Knee brace



April 9, 1963 H. E. LEWIS 3,084,685

KNEE BRACE 2 Sheets-Sheet 1 Filed May 25, 1961 I I INVINTOR.

H. E. LEWIS KNEE BRACE April 9, 1963 2 Sheets-Sheet 2 FiledMay 25, 1961 & INViNTOR.

United States Patent Ofiice 3,684,685 Patented Apr. 9, 1963 3,084,635 KNEE BRACE Hector E. Lewis, Cincinnati, Ohio, assignor to Surgical Appliance Industries, Inn, Cincinnati, Ohio, :1 corporation of Ohio Filed May 25, 1961, Ser. No. 114,283 6 Claims. (Cl. 128-80) This invention relates to knee braces of the type adapted to support an injured or weakened knee joint, and is particularly directed to a knee brace comprising an elastic woven sleeve for embracing the knee area of a wearers leg and a plurality of pressure members carried by the sleeve for applying pressure to the ligaments at the forward and side portions of the knee. The present application is a continuation-in-part of the copending application of Hector E. Lewis for Knee Brace, Serial No. 737,943 and nOW abandoned.

In the past, it has been conventional to provide elastic sleeve knee braces for supporting injured or weakened knee joints. While these sleeves have been beneficial in some cases, the support afforded the knee has not been adequate in many instances. In an attempt to provide greater pressure upon the knee area it has been proposed to provide a knee brace with hinged metal straps or springs which tend to press pads against certain areas of the knee. Such hinged knee braces are inherently subject to two serious defects. In the first place, the braces are cumbersome and bulky; and therefore somewhat uncomfortable. In the second place, when the wearer of such a brace bends his knee, and actually needs greater support, the metal hinge members tend to separate and move away from the knee joint so that the wearer, in fact, receives less support.

The principal object of the present invention is to provide a compact knee brace which overcomes the above mentioned disadvantages and is effective to provide firm pressure over the knee ligaments at all times, whether the knee is straightened or bent. More particularly the present invention contemplates a knee brace comprising an elastic sleeve adapted to fit over the leg area at the knee and carrying a plurality of longitudinal or vertical pockets adapted to receive elongated pressure elements. These pressure elements are in the form of flattened helical springs which are interleaved and overlapped so that the pressure members can be deformed in any transverse plane but resist elongation. In the preferred embodiment, the pockets are formed of an inelastic material extending substantially the full length of the sleeve and the springs are of substantially the same length as the length of the pockets.

When the knee is in a straight position, the spring pressure members function to rigidify the sleeve and to apply increased pressure over the ligament areas. When the knee is bent, the springs conform to the shape of the knee and therefore remain in contact with the knee over the ligament areas. These springs and their inelastic pockets, which are disposed over the front and side areas of the knee, are placed in tension when the knee is bent. Since the pockets are inelastic and cannot appreciably stretch, this tension force is transmitted through the springs to the ligament areas. Also shifting of the springs within the pockets is effectively resisted by friction so that the tension of the springs themselves augments the force applied to the ligaments.

In addition to the pockets and springs, another feature of the present knee brace is the provision of rubber pads in the rear interior portion of the brace. These pads are disposed to overlie the rear area of the wearers knee and are effective to prevent the sleeve from bunching or binding in this area, thereby greatly contributing to the wearers comfort.

In addition to the advantages of the knee brace disclosed above, I have determined that a knee brace having still additional advantages can be formed by providing a knee brace comprising an elastic sleeve having a plurality of flattened helical springs located in pockets disposed at each forward side portion of the sleeve as described above. In this modification, the knee brace is further provided with an opening disposed over the wearers kneecap. At either side of this opening, mounted in pockets on the inside of the sleeve beneath the springs, are two tapered resilient pads. These pads are positioned to overlie the joint space of the knee area.

In this embodiment, the springs not only provide a generally conforming pressure over the entire joint area, but additionally the springs exert pressure on the pads to cause areas of relatively high pressure concentration across the joint space. This pressure is applied directly to the side of potential injury, i.e., the cartilage areas; and is effective to prevent lateral or medial rotation at the joint as well as anterior or posterior glide and protrusion of the lateral or medial cartilages. Additionally, the brace provides some resistance to complete fiexion of the knee which might be injurious under some circumstances.

The modified form of pad described above not only is extremely advantageous because of the greatly improved support given the knee joint, but also the pad provides the highly unexpected advantage that it prevents bunching of the brace in the back of the wearers knee. Thus, the present brace is much more comfortable to wear than prior art braces of the sleeve type.

These and other objects and advantages of the present invention will be more readily apparent from a further consideration of the following detailed description of the drawings illustrating a preferred embodiment of the invention.

In the drawings:

FIGURE 1 is a side view showing a knee brace constructed in accordance with the present invention applied to the flexed knee of a wearer.

FIGURE 2 is a front view of the knee brace.

FIGURE 3 is 'a cross-sectional view taken along line 3-3 of FIGURE 2.

FIGURE 4 is a partial fragmentary view of a spring pressure element of the present invention.

FIGURE 5 is a front view of a modified form of knee brace constructed in accordance with the present invention.

FIGURE 6 is an interior view of the brace showing the manner in which a side pad is mounted in the brace.

FIGURE 7 is a cross-sectional view taken along line 7-7 of FIGURE 5.

As shown in FIGURES 1 and 2, one form of kneecap, or brace, 10 constructed in accordance with the present invention comprises a sleeve member 11 preferably formed of a one-way elastic material which is stretchable in a longitudinal direction. Sleeve 11 preferably tapers slightly from the top to bottom and is slightly curved (the front surface being convex) to conform to the contour of the knee. This sleeve carries a plurality of longitudinal pocket forming strips '12, 13, 14, 15, 16 and 17. These strips are formed of an inelastic material and in the specific embodiment shown extend from the uppef seam 18 to the lower seam 20 of the sleeve. The pockets defined by strips 12-14 are disposed to overlie and engage portions of the wearers knee extending from the right-hand edge of the kneecap to the ligaments running along the side of the knee as shown in FIGURE 1. Each of the strips 12-14 is parallel to the other two strips on the righthand side of the brace. Springs :15, 16 and 17 are disposed to overlie the left side of the knee from the ligaments adjacent to the left-hand edge of the kneecap to 'the ligaments at the rear left-hand side of the knee.

aoeaeee Each of the pockets is stitched to the sleeve member 11 and confines an elongated pressure element 21. Each of the pressure elements extends substantially the full length of the pocket; by way of example, from the bottom stitch line 22 to the top stitch line 23 of pocket 16. Each of the pressure members 21 is a flat member which initially can be flexed in any transverse direction, or twisted, but which resists elongation.

More particularly, each pressure member 21 comprises one or more flattened helical spring elements. In the preferred embodiment, each member 21 comprises two component spring 24 and 25. These springs are interleaved and are overlapped as shown in FIGURE 4. Each of the pressure members is provided with a generally U- shaped cap 26 in the form of a channel element which receives the ends of the helical spring elements. Caps 25 are compressed tightly against the spring elements to hold them in assembled relationship.

The rear portion of the knee brace carries a soft rubber pad 27. This pad is encased in a suitable pocket 30, the pocket being sewn to the sleeve along a vertical seam 32 so that the free edges of the pockets 33 and 34 are free to move relative to the main sleeve 11. The function of pad 27 is to increase the comfort of the brace to the wearer by preventing the brace from pinching at the rear of the knee area.

When the knee brace is applied by a wearer, he slips his foot through sleeve 11 and pulls on the sleeve to bring it into the position shown in FIGURE 1. In this position the upper seam of the sleeve resides above the knee joint and the lower seam of the sleeve resides beneath the knee joint. The strips carried by pockets 12, 13 and 14 engages the right-hand areas of the knee, the most forward of the strips lying over the ligament area adjacent to the kneecap, the other strips covering the ligaments on the side of the knee.

In a similar manner, strips 21 carried by pockets '15, 16 and 17 cover the ligament areas of the knee joint on the left-hand front and side of the knee. These springs increase the support given to the knee joint even when the knee is straight, since the strips rigidify the sleeve and tend to resist any local deformation of the sleeve, thereby applying a greater pressure on the ligament areas.

More importantly, however, when the knee is bent, the strips are bent and remain in contact with the knee in the manner shown in FIGURE 1. When the knee is bent in this, manner the forward edge of the sleeve tends to stretch, placing the inelastic pockets in tension. The tension force of these pockets is in turn transmitted evenly to the knee through the springs carried in the pockets. Additionally, these springs tend to stretch; but this stretching is limited by the spring tension. While the ends of the springtend to shift within the pockets during the bending movement, the friction of the cloth against the spring resists thismovement and further augments the pressure applied by the spring to the knee.

While the springs. apply a firm support to the ligament areas of the knee, the surfaces of the springs remain relatively smooth so that the wearer encounters no dis comfort. At the same time, the pad 27 inserted in the rear of the sleeve prevents the sleeve from bunching or binding against the rear portion of the knee to further enhance the wearers comfort.

A mod fied form of knee brace is shown in FIGURE 5. As is there shown, the knee brace 35 comprises an elastic sleeve member 36 preferably formed of one-way stretch material which is stretchable in a circumferential direction. As in the first embodiment, sleeve 36 tapers slightly from the top to bottom and is slightly curved so that the forward surface of the sleeve is convex. Also, as in the previously described embodiment, sleeve 36 carries a plurality of vertical pocket forming strips 37, 38, 39, 40, 4-1 and 42. These strips are formed of an inelastic material and stitched about their periphery to the outer surface of the sleeve. I

As is shown in FIGURE 7, strips 37-39 extend over the forward portion of the left-hand side of the brace (as viewed from the front), while strips -404-2 overlie the forward portion of the left-hand side of the brace. Each of the pockets formed by the slips 3742 receives a flattened helical spring 43 identical to the spring members 21. The front of the sleeve 36 is provided with an elliptical opening 44. This opening is positioned to receive a portion of the wearers kneecap when the brace is bent. Inside of the brace adjacent to each side of the opening 44 are two elastic pockets 45 and 46. These pockets are formed 'by stitching generally heart-shaped pieces of elastic material to the inner surface of sleeve 36. Pockets 45 and 46 have open portions adjacent to front opening 44. A tapered, generally heart-shaped pad 4-747, formed of a suitable resilient material such as slow rebound closed cellular polyvinyl chloride foam, or the like, is inserted in each of these pockets.

When this modified brace is placed upon the wearers knee, the elastic sleeve and stays function to apply pressure over the entire knee area of the wearer. At the same time, the pressure transmitted from the springs through the resilient pads applies a localized high pressure over the opposed joint areas of the knee. The inherent rigidity of this knee brace construction elfectively restrains relative lateral and medial rotation of the bones at the knee joint as well as anterior or posterior glide at the joint. Also, the pressure applying pads effectively prevent lateral or medial protrusion of the cartilages. It has also been observed that the pads prevent the sleeve from binding with the result that the brace is comfortable to wear. This modified form of brace has been found particularly useful in post-operative care of wearers having knee operations as well as in post-injury treatment.

Having described my invention, I claim:

1. As a new article of manufacture, a knee brace comprising a one piece, continuous, generally cylindrical sleeve formed of woven elastic material and dimensioned to cover the leg area at the knee joint, said sleeve having a forward portion, a rear portion and side portions intermediate the forward portion and rear portion, a plurality of longitudinal strips formed of an inelastic material, said strips being stitched to the forward and side portions of said sleeve on the exterior surface thereof and extending substantially the full length of the sleeve, said longitudinal strips cooperating with said sleeve to form a plurality of pockets, said pockets being disposed on each side of the wearers knee and being laterally spaced from one another, a plurality of flexible pressure elements, each of said pressure elements comprising two interleaved and overlapping flattened helical springs and end caps for holding said springs in assembled relationship, each of said springs being mounted within one of said pockets and extending over a substantial portion of the length of said sleeve, said pockets being positioned whereby said pressure elements overlie and engage portions of the wearers knee on opposite sides thereof extending from the edges of the kneecap to the ligaments running along the sides of the knee.

2. As a new article of manufacture, a knee brace comprising an elastic sleeve for embracing the knee area of a leg, a flexible pocket disposed in the interior of said sleeve at the rear portion thereof, means securing the center of said pocket to said sleeve, the remaining edges of said pocket being free for movement relative to said sleeve, a rubber pad mounted within said pocket whereby said pad is effective to prevent the sleeve from binding against the rear portion of the wearers knee.

3. As a new article of manufacture, a knee brace comprising a one piece continuous sleeve formed of woven elastic material for embracing the knee area of a leg, flexible pockets disposed in the interior of the sleeve on opposite sides adjacent to the front portion thereof, means securing said pockets to said sleeve, a resilient pad mounted within each of said pockets, a plurality of longitudinal strips formed of a flexible material, said strips being stitched to the forward and side portions of said sleeve on the exterior surface thereof and extending substantially the full length of the sleeve, said longitudinal strips cooperating with said sleeve to form a plurality of pockets, said pockets being disposed on each side of the wearers knee and being laterally spaced from one another, a plurality of flexible pressure elements, each of said pressure elements comprising two interleaved and overlapping flattened helical springs and end caps for holding said springs in assembled relationship, each of said springs being mounted within one of said pockets and extending over a substantial portion of the length of said sleeve, said springs at least partially overlying said pads, said pads being disposed to overlie and engage portions of the Wearers knee on opposite sides thereof extending from the edges of the kneecap to the ligaments running along the sides of the knee.

4. As a new article of manufacture, a knee brace com prising a one piece continuous sleeve formed of woven elastic material having an opening in the front portion thereof for embracing the knee area of a leg, flexible pockets disposed in the interior of the sleeve on opposite sides of said opening adjacent to the front portion thereof, means securing said pockets to said sleeve, a resilient pad mounted within each of said pockets, a plurality of longitudinal strips formed of a flexible material, said strips being stitched to theforward and side portions of said sleeve on the exterior surface thereof and extending substantially the full length of the sleeve, said longitudinal strips cooperating with said sleeve to form a plurality of pockets, said pockets being disposed on each side of the wearers knee and being laterally spaced from one another, a plurality of flexible pressure elements, each of said pressure elements comprising two interleaved and overlapping flattened helical springs and end caps for holding said springs in assembled relationship, each of said springs being mounted Within one of said pockets and extending over a substantial portion of the length of said sleeve, said springs at least partially overlying said pads, said pads being disposed to overlie and engage portions of the wearers knee on opposite sides thereof extending from the edges of the kneecap to the ligaments running along the sides of the knee.

5. As a new article of manufacture, a knee brace comprising a one piece continuous sleeve formed of woven elastic material having an opening in the front portion thereof for embracing the knee area of a leg, flexible pockets disposed in the interior of the sleeve on opposite sides of said opening adjacent to the front portion thereof, means securing said pockets to said sleeve, a resilient pad mounted within each of said pockets, each of said pads tapering rearwardly from a maximum height at the front of the pad, each of said pads having a concave arcuate forward edge conforming generally to the curvature of the opening in the elastic sleeve, a plurality of longitudinal strips formed of a flexible material, said strips being stitched to the forward and side portions of said sleeve on the exterior surface thereof and extending substantially the full length of the sleeve, said longitudinal strips cooperating with said sleeve to form a plurality of pockets, said pockets being disposed on each side of the wearers knee and being laterally spaced from one another, a plurality of flexible pressure elements, each of said pressure elements comprising two interleaved and overlapping flattened helical springs and end caps for holding said springs in assembled relationship, each of said springs being mounted within one of said pockets and extending over a substantial portion of the length of said sleeve, said springs at least partially overlying said pads, said pads being disposed to overlie and engage portions of the wearers knee on opposite sides thereof extending from the edges of the kneecap to the ligaments running along the sides of the knee.

6. As a new article of manufacture, a knee brace comprising a one piece continuous sleeve formed of woven elastic material having an opening in the front portion thereof for embracing the knee area of a leg, flexible pockets disposed in the interior of the sleeve on opposite sides of said opening adjacent to the front portion thereof, means securing said pockets to said sleeve, a resilient pad mounted within each of said pockets, each of said pads tapering rearwardly from a maximum height at the front of the pad, each of said pads having a concave arcuate forward edge conforming generally to the curvature of the opening in the elastic sleeve, a plurality of longitudinal strips formed of a flexible material, said strips being stitched to the forward and side portions of said sleeve on the exterior surface thereof and extending substantially the full length of the sleeve, said longitudinal strips cooperating with said sleeve to form a plurality of pockets, said pockets being disposed on each side of the wearers knee and being laterally spaced from one another, a plurality of flexible pressure elements, each of said pressure elements comprising two interleaved and overlapping flattened helical springs and end caps for holding said springs in assembled relationship, each of said springs being mounted within one of said pockets and extending over a substantial portion of the length of said sleeve, said springs at least partially overlying said pads, said pads extending forwardly beyond said springs, said pads being disposed to overlie and engage portions of the wearers knee on opposite sides thereof extending from the edges of the kneecap to the ligaments running along the sides of the knee.

References Cited in the file of this patent UNITED STATES PATENTS 1,258,052 Stall Mar. 5, 1918 2,195,024 Bullock Mar. 26, 1940 2,270,685 Miller Jan. 20, 1942 2,641,761 Schultz June 16, 1953 2,666,202 Ongley Ian. 19, 1954 3,046,981 Biggs et a1 July 31, 1962 FOREIGN PATENTS 27,396 Great Britain Nov. 28, 1913 663,643 Germany Aug. 10, 1938 

1. AS A NEW ARTICLE OF MANUFACTURE, A KNEE BRACE COMPRISING A ONE PIECE, CONTINUOUS, GENERALLY CYLINDRICAL SLEEVE FORMED OF WOVEN ELASTIC MATERIAL AND DIMENSIONED TO COVER THE LEG AREA AT THE KNEE JOINT, SAID SLEEVE HAVING A FORWARD PORTION, A REAR PORTION AND SIDE PORTIONS INTERMEDIATE THE FORWARD PORTION AND REAR PORTION, A PLURALITY OF LONGITUDINAL STRIPS FORMED OF AN INELASTIC MATERIAL, SAID STRIPS BEING STITCHED TO THE FORWARD AND SIDE PORTIONS OF SAID SLEEVE ON THE EXTERIOR SURFACE THEREOF AND EXTENDING SUBSTANTIALLY THE FULL LENGTH OF THE SLEEVE, SAID LONGITUDINAL STRIPS COOPERATING WITH SAID SLEEVE TO FORM A PLURALITY OF POCKETS, SAID POCKETS BEING DISPOSED ON EACH SIDE OF THE WEARER''S KNEE AND BEING LATERALLY SPACED FROM ONE ANOTHER, A PLURALITY OF FLEXIBLE PRESSURE ELEMENTS, EACH OF SAID PRESSURE ELEMENTS COMPRISING TWO INTERLEAVED AND OVERLAPPING FLATTENED HELICAL SPRINGS AND END CAPS FOR HOLDING SAID SPRINGS IN ASSEMBLED RELATIONSHIP, EACH OF SAID SPRINGS BEING MOUNTED WITHIN ONE OF SAID POCKETS 